Molding assembly with heating and cooling system

ABSTRACT

A molding assembly for making molded parts includes a molding tool having conformal fluid lines that follow contours of a molding surface of the molding tool. The conformal fluid lines are defined in the molding tool during casting by sacrificial displacement lines formed by a three-dimensional printer. A temperature control station is coupled to the molding tool and includes a heating and cooling fluid. A valve station regulates fluid flow to the molding tool.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to the following applications: U.S. patentapplication Ser. No. ______, filed on Feb. 29, 2012, entitled “MOLD COREFOR FORMING A MOLDING TOOL” (Atty. Docket No. 83203377); U.S. patentapplication Ser. No. filed on Feb. 29, 2012, entitled “INTERCHANGEABLEMOLD INSERTS” (Atty. Docket No. 83203382); U.S. patent application Ser.No. ______, filed on Feb. 29, 2012, entitled “MOLD CORE PACKAGE FORFORMING A POWDER SLUSH MOLDING TOOL” (Atty. Docket No. 83225801); U.S.patent application Ser. No. ______, entitled “MOLDING TOOL WITHCONFORMAL PORTIONS AND METHOD OF MAKING THE SAME” (Atty. Docket No.83225806); and U.S. patent application No. Ser. ______, filed on Feb.29, 2012, entitled “ADDITIVE FABRICATION TECHNOLOGIES FOR CREATING MOLDSFOR DIE COMPONENTS” (Atty. Docket No. 83225814), the entire disclosuresof which are hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to a molding assembly with aheating and cooling system.

BACKGROUND OF THE INVENTION

Various molding systems are often used to make parts from moldablematerial. Heating and cooling the molding the components can bedifficult to regulate.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a molding assembly formaking molded parts includes a molding tool having conformal fluid linesthat follow contours of a molding surface of the molding tool. Theconformal fluid lines are defined in the molding tool during casting bysacrificial displacement lines formed by a three-dimensional printer. Atemperature control station is coupled to the molding tool and includesa heating and cooling fluid. A valve station regulates fluid flow to themolding tool.

According to another aspect of the present invention, a molding assemblyfor making molded parts includes a molding tool having a conformal fluidline and a conformal reservoir proximate a molding surface of themolding tool. The conformal fluid line and conformal reservoir aredefined in the molding tool during casting by sacrificial core portionsformed by a three-dimensional sandprinting device. A closed-fluidcircuit couples the molding tool with a temperature control station.

According to yet another aspect of the present invention, a method formaking a molded part includes making a sacrificial mold core packagewith sacrificial displacement lines developed by applying a bindingagent on multiple layers of fine particulate. A molding tool is formedwith conformal lines from the sacrificial mold core package andsacrificial displacement lines. A fluid temperature control station iscoupled with the conformal lines in the molding tool. A moldablematerial is heated and injected into a mold cavity of the molding tool.The moldable material is cooled in the mold cavity.

Still another aspect of the present invention includes a sandprintingdevice adapted to print multiple layers of binder on multiple layers ofsand to form a mold core. The mold core is used to construct either aninsert mold, a base mold, or a molding tool that is used to make moldedparts. The insert mold or molding tool includes conformal lines adaptedto receive a heating fluid and a cooling fluid to aid in the formationof molded parts inside the insert mold or molding tool. The conformallines closely follow a forming surface that is proximate a mold cavityof the insert mold or molding tool.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a top perspective view of a rigid containment box or job boxprior to formation of a mold core package by a sandprinting device;

FIG. 2 is a top perspective view of the rigid containment box of FIG. 1during the spreading of the first layer of fine particulate in the rigidcontainment box;

FIG. 3 is a top perspective view of the rigid containment box of FIG. 1after several passes of a sandprinting device;

FIG. 4 is a top perspective view of the rigid containment box of FIG. 1just before a fresh layer of fine particulates is to be spread over theprint surface of the rigid containment box;

FIG. 5 is a top perspective view of the rigid containment box of FIG. 1with a fresh layer of fine particulate being spread over the printsurface of the rigid containment box;

FIG. 6 is a top perspective view of the rigid containment box of FIG. 1after a full mold core has been printed in the rigid containment box;

FIG. 6A is a side perspective view of the rigid containment box of FIG.1 containing the mold cores with excess unbound sand being removed;

FIG. 7 is a top perspective view of unassembled mold components afterbeing removed from the rigid containment box;

FIG. 7A is a top perspective view of the assembled mold core of FIG. 7;

FIG. 8 is a top plan view of a mold core package of FIG. 7A;

FIG. 9 is a top perspective cross-sectional view taken at line IX-IX ofFIG. 8;

FIG. 10 is a side elevational cross-sectional view of the mold corepackage of FIG. 8 taken at line X-X;

FIG. 11 is a top perspective cross-sectional view of a mold core packageduring filling of molten metal into a casting area defined by the moldcore package;

FIG. 12 is a top perspective cross-sectional view of formation of a moldcore package after introduction of the molten metal to the mold corepackage;

FIG. 12A is a side elevational cross-sectional view of the mold corepackage of FIG. 12;

FIG. 13 is a top perspective view of the resulting molding tool formedfrom the mold core package;

FIG. 14A is a top perspective cross-sectional view of one embodiment ofa conformal line construction extending through a molding tool.

FIG. 14B is a top perspective cross-sectional view of another embodimentof a conformal line extending through a molding tool;

FIG. 14C is a top perspective cross-sectional view of another embodimentof a conformal line extending through a molding tool;

FIG. 14D is a top perspective cross-sectional view of another embodimentof a conformal line extending through a molding tool;

FIG. 14E is a top perspective cross-sectional view of another embodimentof a conformal line extending through a molding tool;

FIG. 14F is a top perspective cross-sectional view of another embodimentof a conformal line extending through a molding tool;

FIG. 14G is a top perspective cross-sectional view of another embodimentof a conformal line extending through a molding tool;

FIG. 14H is a top perspective cross-sectional view of another embodimentof a conformal line extending through a molding tool;

FIG. 141 is a top perspective cross-sectional view of another embodimentof a conformal line extending through a molding tool;

FIG. 15A is a top perspective cross-sectional view of one embodiment ofa conformal reservoir extending through a molding tool;

FIG. 15B is a top perspective view of the conformal reservoir andmolding tool of FIG. 15A;

FIG. 15C is a top perspective cross-sectional view of another embodimentof a conformal reservoir extending through a molding tool;

FIG. 15D is a top perspective view of the conformal reservoir andmolding tool of FIG. 15C;

FIG. 15E is a top perspective view of another embodiment of a conformalreservoir extending through a molding tool;

FIG. 15F is a top perspective view of yet another embodiment of aconformal reservoir extending through a molding tool;

FIG. 15G is a top perspective view of yet another embodiment of aconformal reservoir extending through a molding tool;

FIG. 16 is a top perspective view of the molding tool, which representsa first mold half, prior to connection with a complementary second moldhalf;

FIG. 16A is a top perspective view of the first mold half and secondmold half of FIG. 16 after connection;

FIG. 17 is a top perspective view of a molded part being removed fromthe first mold half and second mold half;

FIG. 18 is a top perspective cross-sectional view of formation of aninsert mold tool in a mold core package;

FIG. 19 is a side elevational cross-sectional view of the insert moldtool of FIG. 18;

FIG. 20 is a top perspective cross-sectional view of the insert moldtool after removal from the mold core package;

FIG. 21 is a top perspective view of the first and second insert moldtools prior to installation into first and second base molds;

FIG. 21A is a top perspective cross-sectional view of the moldingassembly of FIG. 21;

FIG. 22 is a top perspective view of the molding assembly of FIG. 21during molding of a part;

FIG. 23 is a top perspective view of the molding assembly of FIG. 21during removal of the molded part;

FIG. 24 is a schematic view of a temperature control station inconnection with a mold assembly and introducing a heating fluid to themolding assembly;

FIG. 25 is a schematic view of a temperature control station coupledwith a mold assembly and introducing a cooling fluid to the moldassembly;

FIG. 26 is a schematic view of one embodiment of a heating system foruse with a molding assembly;

FIG. 27 is a schematic view of one embodiment of a cooling system foruse with a molding tool of the present invention;

FIG. 28 is a top perspective exploded view of a sand mold packagecomprising a cope mold, a drag mold, and a core;

FIG. 29 is a top perspective view of the sand mold package of FIG. 28with the core inserted into the drag mold;

FIG. 30 is a top perspective view of the sand mold package of FIG. 28with the cope and drag molds positioned adjacent one another inpreparation for casting of a molten material;

FIG. 31 is a perspective view of a cast part produced from the sand moldpackage of FIG. 28 with the sand mold package of FIG. 28 being brokenaway; and

FIG. 32 is a perspective view of the cast molding tool as produced bythe sand mold package of FIG. 28.

DETAILED DESCRIPTION OF THE EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the invention as oriented in FIG. 1. However, itis to be understood that the invention may assume various alternativeorientations, except where expressly specified to the contrary. It isalso to be understood that the specific devices and processesillustrated in the attached drawings, and described in the followingspecification are simply exemplary embodiments of the inventive conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

Referring to FIGS. 1-27, a mold core package 10 is illustrated. The moldcore package 10 is used to form a molding tool 12. The mold core package10 includes a plurality of stacked particulate layers 14 having abinding agent 16. The plurality of stacked particulate layers 14 formsacrificial walls 18. An elongate sacrificial particulate line 20extends through the mold core package 10 and defines a conformal line 22in the molding tool 12. A mold cavity 26 is defined by the plurality ofstacked particulate layers 14.

It is contemplated that the molding tool 12 could be used in any of avariety of molding operations. Such molding operations may includeinjection molding, foam molding, blow molding, thermoforming, transfermolding, reaction injection molding, compression molding, extrusion,etc. The molding tool 12, as set forth in the following description, isused for injection molding applications. However, it will be understoodby one having ordinary skill in the art that the molding tool 12 that isfabricated by the use of the mold core package 10 can be used for any ofthe aforementioned molding applications.

Referring now to FIGS. 1-6, a pattern box or job box 40 formed from anyof a number of materials including wood, metal, etc., is positionedbelow a printing device 42. The job box 40 defines a print area 44within which the mold core package 10 (FIG. 8) will be constructed fromthe plurality of stacked particulate layers 14. The printing device 42includes a hopper 46 and a deposition trough 48, which lays a thin layerof activated fine particulates 50, such as silica, sand, ceramic-sandmixtures, etc., inside the print area 44. The particulates 50 may be ofany size, including 0.002 mm to 2 mm in diameter. The printing device 42also includes a binder deposition device or a binder dispenser 52. Asdisclosed in detail below, the binder dispenser 52 sprays a thin layerof a binder or binding agent 16 in the shape of a single layer of thedesired mold core package 10. Repetition of the layering of sand andspraying of binding agent 16 by the binder dispenser 52 on the fineparticulates 50 results in the production of three-dimensional (3D) moldcore patterns 10. The 3D mold core patterns 10 are generated over alength of time sufficient to print on each thin layer of fineparticulates 50. The mold core package 10 generated will ultimately beused to fabricate the molding tool 12 that is used to make molded parts.

Referring to FIG. 1, initially, a computer-aided design (CAD) programrunning in a computer 60 coupled with the printing device 42 thatincludes the desired shape of the end product is fed into the CADprogram of the printing device 42. It is contemplated that CAD, or anyother form of 3D modeling software, can be used to provide sufficientinformation for the 3D printing device 42 to form the desired mold corepackage 10 (FIG. 8). Prior to activation of the 3D printing device 42, apredetermined quantity of the fine particulates 50 is dumped into thehopper 46 by a particulate spout 62, along with an activation coating oractivator 70 supplied by an activator spout 72. Although the illustratedembodiment uses a fine sand as the fine particulate 50, as noted above,the fine particulate 50 may include any of a variety of materials orcombinations thereof. The fine particulates 50 are mixed in the hopper46 with the activator 70. The mixture of fine particulates 50 andactivator 70 may be mixed by an agitator 74 or other such agitatingdevice such that the fine particulates 50 become activated. After thefine particulates 50 and activator 70 have been thoroughly mixed, thefine particulates 50 are moved to the deposition trough 48.

Referring now to FIGS. 2 and 3, after the fine particulates 50 have beenmoved to the deposition trough 48, the fine particulates 50 are spreadacross the print area 44 in a fine even layer by the deposition trough48. After being spread in a thin layer on the print area 44 in the jobbox 40, the activated fine particulates 50 are sprayed with the bindingagent 16. The binding agent 16 comes from the binder dispenser 52, whichsprays a thin layer of the binding agent 16 in a pattern 80 thatrepresents a first thin cross-sectional layer of the desired mold corepackage 10 (FIG. 8). After the binding agent 16 has been sprayed,another mixture of fine particulates 50 and activator 70 is prepared anddumped into the deposition trough 48. The deposition trough 48 thendispenses another layer of activated fine particulates 50 over thepreviously spread fine particulates 50 layer in the job box 40. Thebinder dispenser 52 passes over the print area 44 again, spraying a thinlayer of the binding agent 16 in the pattern 80 that represents a secondthin cross-sectional layer of the desired mold core package 10 adjacentto the first thin cross-sectional layer. These steps are repeated manytimes until every cross-sectional layer of the mold core package 10 hasbeen printed (FIG. 6). Using this mold core construction technique,virtually any shape of the mold core package 10 can be formed. Further,the mold core package 10 can have internal structural features thatcannot otherwise be created by other known methods. Specifically, themold core package 10 can be constructed to include the plurality ofsacrificial particulate lines 20 (FIG. 6A) that extend in and around themold core package 10. The plurality of sacrificial particulate lines 20are created from the binding agent 16 and fine particulates 50 in thesame way the mold core package 10 is formed. As will be disclosed infurther detail herein, the plurality of sacrificial particulate lines 20are used to define the conformal channels or lines 22 (FIG. 13), whichallow for rapidly heating and cooling of the molding tool 12 (FIG. 13)during the injection molding of the parts.

Referring now to FIGS. 7 and 7A, it also contemplated that any ofinterlocking features for connecting components of a mold core packagemay be utilized. In the illustrated embodiment, a composite mold core 92having a multitude of components of a mold core package 93A, 93B, 93C,and 93D adapted for insertion into a job box. In certain instances, whenlarge molding tools 12 (FIG. 13) are being formed, several components ofa mold core package may need to be fitted together to form the moldtools 12. As shown, the components of a mold core package 93A, 93B, 93C,and 93D are combined using sacrificial connectors 94 that are adapted toengage receiving slots 95 in each of the components of a mold corepackage 93A, 93B, 93C, and 93D. The components of a mold core package93A, 93B, 93C, and 93D otherwise function similarly to the mold corepackage 10 discussed in this disclosure.

As shown in FIGS. 8-11, the 3D mold core package 10 includes a formingsurface 100 that generally represents the shape of a part that willultimately be molded. The mold core package 10 also includes theplurality of sacrificial particulate lines 20 that define conformallines 22 (FIG. 13) in the molding tool 12. The mold core package 10 alsohas a shape that includes the size and positioning of the conformallines 22, which are elongate passageways through which heating andcooling fluids travel during formation of molded parts in the moldingtool 12. At the same time, conformal lines 22 are disposed about amolding surface 160 (FIG. 13) of what will ultimately be the mold part.The conformal lines 22 assist with heating and cooling of the mold partduring the molding process. As shown in FIGS. 9 and 10, the mold corepackage 10 is prepared for the introduction of a molten material 110.The molten material 110 may be any of a variety of metals, includingcast iron or an alloy. Intermittently spaced core supports 111 may bedisposed in the mold core package 10. The core supports 111 hold thesacrificial particulate lines 20 in place above the forming surface 100.Both the mold core package 10 and plurality of sacrificial particulatelines 20 are used one time to make one molding tool 12. That is, themold core package 10 and the plurality of sacrificial particulate lines20 are generally destroyed during creation of the molding tool 12 afterthe molten material 110 has solidified in the mold core package 10. Analloy, such as that shown and described in U.S. Provisional PatentApplication No. 61/268,369, entitled “Method of Producing a Cast Skin orSlush Mold,” and PCT International Publication No. WO 2010/144786,entitled “Low CTE Slush Molds with Textured Surface, and Method ofMaking and Using the Same,” which are incorporated herein in theirentirety, may be poured into the mold core package 10.

Referring now to FIGS. 11-13, the molding tool 12 is made by pouring themolten material 110 into the mold core package 10. The molten material110 fills all the empty space in and around the mold core package 10,sacrificial walls 18, and sacrificial particulate lines 20. The moltenmaterial 110 may incinerate some or all of the binding agent 16 in thethin particulate layers 14. After the insertion of the molten material110 into the mold core package 10, the mold core package 10 is placed ina furnace where the heat volatilizes the binding agent 16 in the moldcore package 10. The cast molding tool 12 is then broken away from themold core package 10 by breaking up the sacrificial walls 18, and anyremaining sand can be flushed or washed off the molding tool 12.Similarly, the binding agent 16 in the sacrificial particulates lines 20also volatilizes such that the conformal lines 22 can be cleaned outwith a brush or a power-sprayer that washes the fine particulates 50 outof the conformal lines 22.

Further, it is contemplated that thin containment walls can be printedaround the mold core package, such as mold core package 10 shown in FIG.11. It is contemplated that the thin containment walls can largelymirror the configuration of the job box 40 shown in FIG. 11. It ispossible to print the thin containment walls using the sandprintingprocess noted above as the mold core package 10 is also printed. Amolten material, such as the molten material 110 noted above, can becast within the thin containment walls printed about the mold corepackage 10. In order for the thin containment walls to withstand thecasting process, a mold core package having thin containment wallsprinted around the mold core package would be nested into foundry sandfor added support. In this way, an additive manufacturing technique canbe used to provide containment walls for containing and forming a castpart when supported by foundry sand. Further, a similar technique ofprinting protective thin containment walls can be used to completelysurround a very delicate and intricate mold core package. In this way,it is contemplated that a protective thin wall containment structure canbe printed, which completely surrounds a delicate mold core package toprotect the mold core package until it is needed for a casting process.The protective thin wall structure can then be broken away to allow thecasting operator to retrieve the mold core package.

As shown in FIGS. 12-13, the molten material 110 is then allowed toharden. The molten material 110 hardens to form the molding tool 12.After hardening, the mold core package 10 is destroyed and internalvoids are cleared out. After the molding tool 12 has been scrubbed andproperly treated, the finished molding tool 12 that is left is capableof forming molded parts during injection molding or other moldingprocesses. The molding tool 12 includes an injection port 120 forinjecting a molding material 122 (FIG. 15B) into the mold cavity 26(FIG. 16A) defined between opposing molding tools 12. In addition, itwill be noted that the conformal lines 22 are provided in the moldingtool 12. The molding tool 12 only represents one-half of a moldingassembly 130 (FIG. 16A), which includes two molding tools 12 thatoperate as first and second mold halves 132, 134 (FIG. 16A) that areused for forming a mold part 140.

Referring now to FIGS. 14A-14H, the sacrificial particulate lines 20(FIG. 12) can be formed with various protuberances that define irregularshapes in the conformal lines 22 after application of molten material tothe mold core package 10. Accordingly, the conformal lines 22 mayinclude a variety of configurations and features, such as turbulenceinducing members. As illustrated in FIG. 14A, the conformal lines 22include a multitude of fins 141 that define recesses 143 in the moldingtool 12. The recesses 143 can provide desired thermodynamiccharacteristics that efficiently convey heat to molding material 110prior to the molding process, or withdraw heat from an already formedpart. In another embodiment, as shown in FIG. 14B, the fins 141 andrecesses 143 are constructed in a spiral pattern, which can createadditional turbulence in the conformal line 22 when the molding tool 12is being heated or cooled. Similar embodiments, such as those shown inFIGS. 14C-14F include a diamond-shaped construction (FIG. 14C), adiamond-shaped construction that is in a spiral configuration (FIG.14D), an ovular construction (FIG. 14E), and an ovular construction thatis in a spiral configuration (FIG. 14F). Additionally, the diameter ofthe conformal line 22 may also change, such that flow through themolding tool 12 increases or decreases as the warming/cooling fluidpasses through the conformal lines 22 (FIG. 14G). These and othervariations on the conformal lines 22 are possible as a result of themanufacturing of the molding tool 12 using a mold core package that ismade by way of the 3D printing process detailed herein. Traditionalcooling lines for molding tools were frequently drilled, thuseliminating the possibility of irregularly shaped conformal lines 22.Additionally, as shown in FIG. 14H, it is contemplated that thelongitudinal extent of the conformal lines 22 may be linear, arcuate,angled, etc. Moreover, the conformal lines 22 can be undulated andinclude portions that are very close to the molding surface 160 (FIG.15A) and other portions that are not close to the molding surface 160,such that different areas of the conformal lines 22 have a differentthermal influence on the molding tool 12 and ultimately the part thatwill be molded. As noted herein, these configurations are made possibleby the 3D printing process detailed herein.

Referring now to FIGS. 15A-15D, it is contemplated that the conformallines 22 may communicate with or become part of one or more conformalreservoirs 145. Each conformal reservoir 145 is formed from asacrificial displacement body that is formed with the mold core package10 during construction of the mold core package 10. The sacrificialdisplacement body can include various recesses that define irregularshapes in the conformal reservoirs 145 after application of moltenmaterial to the mold core package 10. The conformal reservoirs 145 areadapted to provide uniform flow of heating/cooling fluid through themolding tool 12 proximate the molding surface 160 defined in the moldingtool 12. The molding tool 12 may include multiple conformal reservoirs145 that extend across the molding tool 12. As shown in FIGS. 15C and15D, periodic columns 146 are provided that are designed to withstandloads on the molding tool 12 associated with injection moldingpressures. The periodic columns 146 ensure that the injection moldingtool 12 does not break or crack near any of the conformal reservoirs145. Additionally, the molding tool 12 includes separation walls 139that prevent molding material that is injected into the mold cavity 26(FIG. 16A) from entering the conformal reservoir 145 or conformal lines22.

The conformal reservoirs 145 may take on a variety of constructions andmay be located at various distances from the molding surface 160,depending on the desired thermal influence the conformal lines 22 haveon the molding tool 12 and ultimately the part to be molded.Additionally, it is contemplated that the conformal reservoirs 145 mayundulate throughout the molding tool 12. More specifically, portions ofthe conformal reservoirs 145 may be closer to the molding surface 160 ofthe molding tool 12 than other portions of the conformal reservoirs 145,thus providing areas that have higher thermal influence on the moldingsurface 160 than those areas of the conformal reservoirs 145 that arefarther from the molding surface 160.

Referring now to FIGS. 15E-15G, various turbulence inducing members maybe disposed inside the conformal reservoirs 145 to limit stagnation andimprove turbulence of the heating/cooling fluid that flows through thepart during the injection molding process. As shown in FIG. 15E, anumber of fins 147 are disposed at angles relative to one another andthat encourage flow into and around the fins 147. Alternatively, asshown in FIG. 15F, a plurality of baffles 148 are disposed atintermittent positions inside the conformal reservoir 145, which act toinfluence the flow of the heating/cooling fluid flowing through theconformal reservoir 145, and also minimize thermal influence of theheating/cooling fluid at the locations of the baffles 148. In yetanother embodiment, as shown in FIG. 15G, a plurality of intermittentprojections 149 extend into the conformal reservoir 145, therebyinfluencing flow and stagnation of heating/cooling fluid in theconformal reservoir 145. Although the projections 149 illustratedinclude a cylinder-shaped construction, it will be understood that theprojections 149 could take on many different shapes. It will also beunderstood by one having ordinary skill in the art that any of a varietyof different architectures can be formed in the molding tool 12 as adirect consequence of being constructed from the 3D printing processdisclosed herein. During the molding process, the turbulence members aredefined by a recess in the mold core that is later filled by the moltenmaterial during fabrication of the molding tool 12.

Referring now to FIGS. 16 and 16A, a first mold half 132 is connectedwith a second mold half 134 that was previously formed and iscomplementary in shape. The first mold half 132 and the second mold half134 represent molding tools 12 formed using the printing techniquedescribed in detail with reference to FIGS. 1-14. The mold cavity 26between the first mold half 132 and the second mold half 134 representsthe shape of the mold part 140 (FIG. 17) that is to be formed. The firstmold half 132 and the second mold half 134 are connected via pins 144disposed about corners of each of the first and second mold halves 132,134 and which secure the first mold half 132 and the second mold half134 laterally (X and Y directions). At the same time, a press 150secures the first mold half 132 to the second mold half 134 in avertical direction. After the first mold half 132 and the second moldhalf 134 have been secured together, the molding material 122 isinjected through the injection port 120 at a high pressure.Consequently, the mold cavity 26 defined between the first mold half 132and the second mold half 134 is filled with the molding material 122. Atthe same time, a heating fluid 152 (FIGS. 24 and 25) is pumped into aninlet 153 through the conformal lines 22, which are disposed proximatethe molding surface 160 of the first mold half 132 and the second moldhalf 134 and leaves through an outlet 155. The heating fluid 152 warmsthe molding surface 160 of the first mold half 132 and the second moldhalf 134, causing proper flow of the molding material 122 into the moldcavity 26. After the mold cavity 26 has been completely filled withmolding material 122, the conformal lines 22 are drained of the heatingfluid 152. The conformal lines 22 are then filled with a cooling fluid154 to rapidly cool the molding material 122 disposed in the mold cavity26. It is contemplated that the cooling fluid 154 and heating fluid 152may be the same fluid. Alternatively, the cooling fluid 154 may be afirst fluid that operates well in a chilled condition, and the heatingfluid 152 may be a second fluid that operates well in a heatedcondition. After a predetermined length of time, the first mold half 132is separated from the second mold half 134 and the mold part 140 (FIG.17) is removed. The first mold half 132 and the second mold half 134 arenow ready for reconnection and introduction of additional moldingmaterial 122 to form more mold parts 140.

Yet another embodiment of the present invention includes an insertmolding assembly 168 (FIG. 21) that has first and second insert molds170, 172, also known as a cavity tool 170 and a core tool 172, adaptedto engage first and second base molds 174, 176, respectively. Asillustrated in FIGS. 18-20, the first and second insert molds 170, 172are formed in a similar process, as outlined above with respect to FIGS.1-14. The same 3D printing process is utilized, but the 3D printingprocess is used to form first and second insert molds 170, 172 ratherthan the finished molding tool 12. The first and second insert molds170, 172 provide for quick connection to the first and second base molds174, 176, thereby allowing a user to quickly change out the first andsecond insert molds 170, 172 from the first and second base molds 174,176, thereby improving the rate at which different mold parts 140 can bemade in a molding facility. Conformal lines 22 and conformal reservoirs145 can be formed in either or both of the insert molds 170, 172. It isalso contemplated that the conformal lines 22 may be in fluidcommunication with conformal lines 22 in the first and second base molds174, 176 or with relay lines in the first and second base molds 174,176. The conformal lines 22, conformal reservoirs 145 and any relaylines are fabricated by forming sacrificial core portions, such assacrificial displacement lines and sacrificial displacement bodies in amold core package 10 prior to introduction of molten material to themold core package 10.

As illustrated in the embodiment of FIGS. 21-23, the first and secondinsert molds 170, 172 are designed for insertion into the first andsecond base molds 174, 176, respectively. The first and second insertmolds 170, 172 are aligned with pins 180 disposed about corners of thefirst and second base molds 174, 176. While the pins 180 in theembodiment shown in FIGS. 21-23 are adapted to engage the first andsecond insert molds, 170, 172, the present invention is not therebylimited to this embodiment. The pins 180 function as a guide featurethat can guide the inserts, the base molds, the inserts and the basemolds, or the pins 180 can be removed entirely. The first base mold 174,first insert mold 170, second insert mold 172, and second base mold 176are then securely connected and molding material 122 is inserted throughan inlet port 179 into the first base mold 174 and through the firstinsert mold 170. The molding material 122 occupies the mold cavity 26defined between the first insert mold 170 and the second insert mold172. The molding material 122 is then heated via the conformal lines 22,which includes heating fluid 152 that is pumped into an inlet 182,through the conformal lines 22, and out an outlet 184 of a moldingsurface 188 of the first and second insert molds 170, 172. After themolding material 122 has been fully pressurized inside the mold cavity26, cooling fluid 154 is inserted into the conformal lines 22 to rapidlycool or chill the molding material 122, thereby forming a hardened moldpart 140. The mold part 140 is then removed from the mold cavity 26(FIG. 23) and the first base mold 174, first insert mold 170, secondinsert mold 172, and second base mold 176 are then reconnected andfilled once again with the molding material 122 to form additional moldparts 140.

Turning now to FIGS. 24 and 25, it is generally contemplated that theheating fluid 152 and the cooling fluid 154 that extend through eitherthe molding tool 12 or the insert molding assembly 168 (collectivelyreferred to as the “molding assembly 200”), is relayed from atemperature control system 202. The temperature control system 202includes the heating fluid 152 and the cooling fluid 154 that are incommunication with the molding tool 12 or the insert molding assembly168. When the molding assembly 200 is to be heated, typically during theinitial insertion of molding material 122 into the molding assembly 200,a valve station 204 opens warmside valves 206 that allow communicationof the heating fluid 152 from a heated fluid reservoir 208 to themolding assembly 200. At the same time, coolside valves 210 that controlcommunication of the cooling fluid 154 from a cooled fluid reservoir 212to the molding assembly 200 are closed, such that the cooling fluid 154cannot reach the molding assembly 200. After the molding assembly 200has reached the desired temperature for the desired length of time, theheating fluid 152 is then returned to the heated fluid reservoir 208,and the warmside valves 206 that allow fluid communication of theheating fluid 152 to the molding assembly 200 are closed. At the sametime as shown in FIG. 25, the coolside valves 210 that were closedbetween the cooled fluid reservoir 212 and the molding assembly 200 areopened, such that cooling fluid 154 can flow to the molding assembly200, consequently cooling the molding material 122 and forming thehardened mold part 140.

FIG. 26 illustrates one embodiment of a heating system 300 for use withthe molding assembly 200, as described above. The heating system 300includes a heating fluid line 302 that passes a dirt trap 304, whichremoves any dirt or debris that may be in the heating fluid 152. Theheating fluid 152 then passes a degassing tank 306. The degassing tank306 removes undesirable gases and other impurities from the heatingfluid 152 before being moved by a pump 308 to a heater 310. The heatingfluid 152 is generally cooler than desired, as the heating fluid 152 isreturning from the molding assembly 200 where heat transfer occurred.Thus, it is desirable to reheat the heating fluid 152 in the heater 310.The heater 310 raises the temperature of the heating fluid 152 to adesired temperature before passing the heating fluid 152 through a heatexchanger 312, which assists in regulating the heat of the heating fluid152. The heat exchanger 312 is coupled with a cooling water outlet 314and a cooling water supply 316 that prevents the heat exchanger 312 fromreaching too high of a temperature. The heating fluid 152 then passesfirst and second temperature sensors 317, 318 that confirm thetemperature of the heating fluid 152 before the heating fluid 152 passesa flow meter 320 that provides a volumetric flow rate of the heatingfluid 152 flowing to the molding assembly 200.

Referring now to FIG. 27, a cooling system 400 is illustrated that isadapted for connection with the molding assembly 200. The cooling fluid154 passes through a dirt trap 402 and into a cooling tank 404, wherethe cooling fluid 154 is cooled to a desirable temperature. The coolingfluid 154 is generally warmer than desired, as the cooling fluid 154 isreturning from the molding assembly 200 where heat from the moldingassembly 200 and mold part 140 was transferred to the cooling fluid 154.Thus, it is desirable to recool the cooling fluid 154 in the coolingtank 404. A temperature sensor 406 monitors the temperature in thecooling tank 404. The cooling tank 404 is cooled by a submergedevaporator 408 disposed in the cooling tank 404. The submergedevaporator 408 is linked with a refrigerant that flows past a compressor410 that is disposed between high and low pressure cutouts 412, 414.After moving past the compressor 410, the refrigerant is cooled in acondenser 416. After leaving the condenser 416, the refrigerant passes acollector 418 and a check valve 420, as well as a filter dryer 422,before moving past an inspection glass 424, where the refrigerant can bereviewed for color, consistency, impurities, etc. The refrigerant thenpasses through an expansion valve 426, where the refrigerant coolsrapidly before entering the cooling tank 404. As the refrigerant passesthrough the cooling tank 404, the refrigerant cools the cooling tank 404and the contents of the cooling tank 404, such that the cooling fluid154 in the cooling tank 404 is cooled to a desired temperature. Thetemperature of the cooling fluid 154 is monitored by the temperaturesensor 406. Cooling fluid 154 is then withdrawn from the cooling tank404 via a pump and pushed to the molding assembly 200, and morespecifically, to the conformal lines 22 in the molding assembly 200.

Although FIGS. 26 and 27 are exemplary embodiments of heating andcooling systems that may be used in conjunction with a mold, it iscontemplated that other heating and cooling systems may be used inconjunction with the mold, and specifically the molding tool, insertmolds, and base molds, as disclosed above.

Referring now to FIG. 28, another embodiment of the present invention isshown wherein a sand mold package 530 includes an upper mold or copemold 532, a lower mold or drag mold 534, and a core 522. The sand moldpackage 530 is made entirely of mold and core components, which areprinted from a sandprinter, and subsequently removed from the job box.The sand mold package 530, as shown, is being prepared for casting of amolten material in a similar fashion as described above.

Referring now to FIGS. 29 and 30, the core 522 is shown inserted into acavity 539 disposed on a top surface of the drag mold 534, wherein thecavity 539 forms a molding cavity, which is defined by the union of thecope mold 532 having a cavity 537 and the drag mold 534. As shown inFIG. 30, the sand mold package 530 is fully assembled with the cope mold532 and the drag mold 534 stacked upon one another. As shown in FIG. 28,a mold cavity is created by the union of cavities 537, 539 disposed inboth the cope mold 532 and the drag mold 534, respectively. As shown inFIGS. 28-30, apertures 536 and 538 are shown disposed on the uppersurface of the cope mold 532. Aperture 536 represents an access pointfor pouring a molten material into the sand mold package 530 asassembled in FIG. 30. The access point 536 further connects to a seriesof runners 541, as shown in FIG. 28, which allows the molten material topass from the cope mold 532 to the drag mold 534 through access point536. In this way, the runners 541 fill the mold cavity created by theunion of cavities 539, 537 of the cope mold 532 and the drag mold 534,respectively, from the bottom up. As the molten material fills the moldcavity, excess molten material begins to fill risers 538 disposed on atop surface of the cope mold 532. The risers 538 help the castingoperator to know when the mold cavity of the sand mold package 530 hasbeen filled, and also allow for molten material to be available to fillany areas of the mold cavity as the molten material settles.

Once the molten material has solidified within the sand mold package530, the sand mold package 530 is broken away, as shown in FIG. 31, toreveal a cast part 540. As shown in FIG. 32, the cast part 540 is shownwith casting material used to fill the access point 536, runner system541, and risers 538 of the sand mold package 530 shown in FIGS. 28-30being hardened and solidified on a molding tool 542. These castconfigurations indicated as 536A, 538A, and 541A are machined off orotherwise removed from the molding tool 542 to reveal a tool that isready for use in a molding process.

The mold core package, and the components included therein, as well asthe methods of making tools from the mold core package, as disclosedherein, provide an improved ability to cool all areas of a molding toolevenly thereby reducing the potential for warpage, cracks, etc. Inaddition, the accuracy associated with making the mold tools from theprinting process provides for better part quality, precision, and designflexibility. The conformal lines allow for improved thermalcapabilities. Multiple lines for heating and cooling are eliminated infavor of integrated heating and cooling conformal lines that can beconfigured to match the desired thermal loading required to improve toolquality as well as tool and part quality. Further, the mold core packagecomponents and the tools made from the mold core package components canbe designed to improve cycle time, thereby increasing part manufacturingcapacity. Class A surfaces that provide a smooth glossy finish (i.e.piano black) can be developed without the need for additional paint orgloss on the finished parts. Further, Class A surfaces having etchedpatterns can be developed by etching a pattern onto a mold surface of amolding tool, thereby resulting in a finished part having a patternembossed thereon.

It will be understood by one having ordinary skill in the art thatconstruction of the described invention and other components is notlimited to any specific material. Other exemplary embodiments of theinvention disclosed herein may be formed from a wide variety ofmaterials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the invention as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desiredembodiment and other exemplary embodiments without departing from thespirit of the present innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present invention. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present invention, and further it is to beunderstood that such concepts are intended to be covered by thefollowing claims unless these claims by their language expressly stateotherwise.

What is claimed is:
 1. A molding assembly for making molded parts,comprising: a molding tool having conformal fluid lines that followcontours of a molding surface of the molding tool, the conformal fluidlines being defined in the molding tool during casting by sacrificialdisplacement lines formed by a three-dimensional printer; a temperaturecontrol station coupled to the molding tool and having a heating andcooling fluid; and a valve station for regulating fluid flow to themolding tool.
 2. The molding assembly of claim 1, wherein the fluid usedfor heating is the same fluid used for cooling.
 3. The molding assemblyof claim 1, wherein the conformal fluid lines include walls having fluidflow-effecting fins.
 4. The molding assembly of claim 1, wherein themolding tool includes a conformal reservoir having a cross-sectionalarea that is different than a cross-sectional area of the conformalfluid lines, the conformal reservoir closely following contours of themold surface.
 5. The molding assembly of claim 1, wherein thetemperature control station includes a refrigerating assembly having anevaporator that is submerged in a fluid collection tank holding coolingfluid.
 6. The molding assembly of claim 1, wherein the temperaturecontrol station includes a closed fluid circuit connected with both aheating assembly and a cooling assembly, and wherein the heatingassembly and cooling assembly thermally adjust the fluid.
 7. A moldingassembly for making molded parts, comprising: a molding tool having aconformal fluid line and a conformal reservoir proximate a moldingsurface of the molding tool, the conformal fluid line and conformalreservoir being defined in the molding tool during casting bysacrificial core portions formed by a three-dimensional sandprintingdevice; and a closed-fluid circuit coupling the molding tool with atemperature control station.
 8. The molding assembly of claim 7, whereinthe conformal fluid line includes walls having projections that effectthe flow of fluid through the conformal fluid line.
 9. The moldingassembly of claim 7, further comprising: flow influencing membersdisposed in the conformal reservoir.
 10. The molding assembly of claim7, wherein the temperature control station includes a heating assemblyhaving a heating element coupled with a heat exchanger.
 11. The moldingassembly of claim 7, wherein the temperature control station includes arefrigerating assembly having an evaporator that is submerged in a fluidcollection tank that holds cooling fluid.
 12. The molding assembly ofclaim 7, wherein the temperature control station includes a closed fluidcircuit connected with both a heating assembly and a cooling assembly,and wherein the heating assembly and cooling assembly thermally adjust athermally-influencing fluid.
 13. The molding assembly of claim 11,wherein the conformal fluid line undulates such that the space betweenthe conformal fluid line and a molding surface of the molding toolvaries.
 14. A method for making a molded part, comprising: making asacrificial mold core package with sacrificial displacement linesdeveloped by applying a binding agent on multiple layers of fineparticulate; forming a molding tool with conformal lines from thesacrificial mold core package and sacrificial displacement lines;coupling a fluid temperature control station with the conformal lines inthe molding tool; heating a moldable material injected into a moldcavity of the molding tool; and cooling the moldable material in themold cavity.
 15. The method of claim 14, further comprising: forming theconformal lines to substantially uniformly follow contours of a moldingsurface of the molding tool.
 16. The method of claim 14, furthercomprising: using a fine sand as the fine particulate.
 17. The method ofclaim 14, further comprising: forming an injection port in the moldingtool that introduces the moldable material to the mold cavity.
 18. Themethod of claim 14, wherein the step of heating a moldable materialfurther comprises: rapidly heating the molding tool by flowing thesingle fluid through the conformal lines of the molding tool, whereinthe single fluid is in a heated condition.
 19. The method of claim 14,wherein the step of cooling the moldable material further comprises:rapidly cooling the molding tool by flowing the single fluid through theconformal lines of the molding tool, wherein the single fluid is in acooled condition.
 20. The method of claim 14, wherein the step offorming a molding tool with conformal lines further comprises:incinerating the binding agent such that the binding agent is removedfrom the sacrificial mold core and sacrificial displacement lines.